Technical

Technical Information
Determining Energy Requirements - Air & Gas Heating
Air & Gas Heating Cryogenics
Industrial gases are usually stored in a liquid state with heat being added to vaporize and boil off the gas as usage requires. General heat equations apply except that pipes, tubes and vessels containing the cryogenic fluid or gas frequently represent a heat source rather than a heat loss. If the size and materials of the tanks or vessels are known, then heat calculations for the temperature rise can be performed as in standard vessel heating or boiler problems. The following example is typical of a cryogenic heating application. Problem Vaporize and preheat 30,000 SCFH of liquid Nitrogen (N2) from -345F to 70F at atmospheric conditions. The properties of N2 from Cryogenic Gas Tables are: Boiling point, -320F Specific heat Btu/lb/F = 0.474 (liq.), 0.248 (gas) Latent heat of vaporization = 85.7 Btu/lb Atm. density of N2 at 32F = 0.0784 lb/ft3. Solution Amount of liquid N2 to be vaporized 30,000 SCFH x 0.0784 lb/ft3 = 2,352 lbs/hr 1. Raise liquid from -345F to -320F (boiling point) T = 25F. kW =Wt x Cp x T x SF 3412 Btu/kW Where: Wt = Weight of material in lbs Cp = Specific heat of the liquid N2 T = Temperature rise in F SF = Suggested safety factor of 20% kW = 2,352 lbs x 0.474 x 25 x 1.2 = 9.8 kW 3412 Btu/kW 2. Vaporize the liquid N2 kW = 2,352 lbs x 85.7 x 1.2 = 70.9 kW 3412 Btu/kW Material Recommendations Ordinary carbon steel is subject to brittle fracture at temperatures below -20F and is generally not recommended. Stainless steel, high nickel bearing alloys or aluminum alloys may be used. Use Teflon for gaskets asTeflon remains pliable at low temperatures. kW = 18 W/ft /hr x 52 ft area x 0.75 hr = 0.70 kW 1,000 W/kW 4. Total kW = 2.86 + 0.47 + 0.70 = 4.03 kW 5. For Oven Applications, add 30% to cover door losses and other contingencies. kWh required (including safety factor) is kWh = kW = 4.03 kW = 5.37 kW x 1.3 = 6.98 kW t 0.75 hrs Equipment Recommendations Several process air heaters, including strip heaters, finstrips, bare tubulars or type OV oven heaters, are suitable for oven heating applications.
3 2

Air & Gas Heating Batch Ovens

Most oven applications consist of heating work product inside an insulated enclosure. Heat loss calculations involve the determination of the heat requirements to heat the enclosure and work product using heated air circulated by natural or forced convection. Any make up or ventilation air must also be considered. The following example outlines the calculation of the heat required for a typical oven heating application. Problem An oven with inside dimensions of 2 ft H x 3 ft W x 4 ft D is maintained at 350F. The oven has sheet steel walls with 2 inches of insulation and is ventilated with 400 cfh (ft3/hr) of 70F air which exhausts to the outside to remove fumes. The oven is charged with 250 lbs of coated steel parts on a steel tray weighing 40 lbs. The process requires the parts to be heated from 70F to 350F in 3/4 hour. Weight of steel = 290 lbs Specific heat of steel 0.12 Btu/lb/F Weight of air = 0.080 lbs/ft3 at 70F Specific heat of air = 0.24 Btu/lb/F Temperature rise = 280F Surface losses with 2 inch insulation = 18 W/ ft2/hr at 280F temperature difference (Graph G-126S) Surface area of oven = 52 ft2 Time = 3/4 hr (0.75) Airflow rate = 400 ft3/hr Solution 1. Calculate kWh required to heat metal. kW = 290 lbs x 0.12 Btu/lb/F x 280F = 2.86 kW 3412 Btu/kW 2. Calculate kWh required to heat ventilated air
3 kW = CFM x lbs/ft x Cp x T x t = 0.47 kW 3412 Btu/kW

Pressure Drop for Process Air Heaters

The pressure drop through TDH and ADH process air heaters with bare tubular or finned tubular elements, CAB heaters with finstrip elements, and ADH and DH air heaters with finned tubular elements will vary considerably depending on product design and construction. Chromalox sales engineering can provide pressure drop calculations for virtually any duct heater (or circulation heater) application. Graphs G-112S3, G-189S1, G-227-2, and G-227ADH on the following page provide guidance for estimating the pressure drop for many Chromalox process air heaters1. Graph G-189S1 can be used for most finned tubular applications providing the elements are mounted in a three or six row configuration. Transitions in Ducts In some air distribution systems, the duct heater may be considerably larger or smaller than the associated ductwork. The duct heater can be adapted to different size ductwork by installing a sheet metal transition. The transition must be designed so that the slope on the upstream side of the equipment is limited to 30 (see below). On the leaving side, the slope should not be more than 45.

3. Raise the temperature of the N2 from boiling point -320F to 70F T = 390F. kW = 2,352 lbs x 0.248 x 390 x 1.2 = 80 kW 3412 Btu/kW Total kW/hr required = 9.8 + 70.9 + 80 = 169.7 Equipment Recommendations Generally, cryogenic applications utilize both a vaporizer unit and a gas preheater. High watt density heaters immersed in the cryogenic fluid can be used for the vaporizer. Standard circulation heaters and watt densities are recommended for gas preheating. Protect the heater terminals from frost and moisture with element seals and liquid tight terminal covers. I-20

Recommended Dimensions for Duct Transitions

30 Max. 45 Max.

Air Flow

Where: CFM = Air flow rate (400) Lbs/ft3 = Density of air (0.080) Cp = Specific heat of air (0.24) T = Temperature rise (280) t = Time in hours (0.75) 3. Calculate surface losses. Since the oven is already at temperature, losses are at full value.

30 Max.

45 Max.

Note 1 Contact the factory for pressure drop calculations for duct heaters mounted lengthwise or in series and for GCH gas circulation heaters. These applications require special calculations for proper application and air handler sizing.

Technical

Technical Information
Determining Pressure Drop - Air and Gas Heating
Graph G-227ADH Pressure Drop Vs. Velocity ADH and ADHT Tubular Element Air Heaters
2.0 1.0 Pressure Drop Inches of Water (Psi = Inches of Water x 0.0361) 0.7 0.5 0.3 Air Flow ADH or ADHT Mounted Crosswise in Duct

Graph G-112S3 Pressure Drop Vs. Velocity Finstrip and CAB Air Heaters
1.0 0.5 0.3 Based on 1-5/8" spacing and 4.7 fins per linear inch Triple Row Double Row Double Row

5" 8.37 M=1 H D 5" A =9. TM H .5" AD M=9 ADH

Pressure Drop Inches of Water (Psi = Inches of Water x 0.0361)

0.1 0.07 0.05 0.03

0.1 0.07 0.05 0.03

0.01 0.007 0.005 0.003

0.01 0 0 5 fps 10 fps 300 fpm 600 fpm 15 fps 20 fps 25 fps 30 fps 35 fps 900 fpm 1200 fpm 1500 fpm 1800 fpm 2100 fpm

Air Velocity (Std. Air) Note Contact factory for pressure drop calculations for ADH/ADHT air heaters mounted lengthwise in duct and ADHT heaters where M is greater than 9.5"

0.001 0 0 5 fps 10 fps 300 fpm 600 fpm 15 fps 20 fps 25 fps 30 fps 35 fps 900 fpm 1200 fpm 1500 fpm 1800 fpm 2100 fpm Air Velocity (Std. Air)

Graph G-189S1 Pressure Drop Vs. Velocity Fintube Elements and Air Heaters
0.7 0.5 Pressure Drop Inches of Water (Psi = Inches of Water x 0.0361) 0.3 Finned Tubulars Mounted Crosswise in Duct Air Flow
R Six
s ow
" 375 18. M=
" =9.5 sM Row

Graph G-227-2 Pressure Drop Vs. Velocity TDH Tubular Element Air Heaters
0.20 0.18
TDH Mounted Lengthwise in Duct Air Flow

0.1 0.07 0.05

ee Thr

0.16 Pressure Drop Inches of Water (Psi = Inches of Water x 0.0361) 0.14 0.12 0.10 0.08 0.06 0.04 0.02
ir rs ate He

0.03

0 0

5 fps 10 fps 300 fpm 600 fpm

15 fps 20 fps 25 fps 30 fps 35 fps 900 fpm 1200 fpm 1500 fpm 1800 fpm 2100 fpm

600 Approximate Terminal Box Temperature (F) 500 400 300 200 100 0 0 200 Data only valid for ADH or ADHT air heaters installed in bottom or sides of duct 400 600 800 1000 1200 Outlet Air Temperature (F)
HA AD

0
s eater Air H ADHT

0 0

5 fps 10 fps 300 fpm 600 fpm

Th re e

Graph ADHTB ADH/ADHT Terminal Box Temperatures Field Wiring Selection Guide

sC ros s wi

Air Velocity (Std. Air) Note Contact factory for pressure drop calculations for finned tubular element air heaters mounted lengthwise in duct.

se A

ny R a tin g

0.01

Row

15 fps 20 fps 25 fps 30 fps 35 fps 900 fpm 1200 fpm 1500 fpm 1800 fpm 2100 fpm

I-21

Technical

Air Velocity (Std. Air)

wis eT DH -24 Le ng thw ise TD H18 Le ng thw ise TD H12

eT wis gth Len
6 DH-

TDH-6 TDH-12 TDH-18 TDH-24 TDH Mounted Crosswise in Duct Air Flow

Len

gth

Technical

Technical Information
Determining Energy Requirements - Air & Gas Heating
Air & Gas Heating with Circulation Heaters
To calculate the heat energy requirements for heating compressed air or gases, the first step is to determine the flow rate in pounds per hour. If the density of the air or gas under the actual pressure is known, the kW requirements can be calculated directly. The following example illustrates this procedure. Example Heat 20 ACFM of air at 30 psig from 60F to 210F. From the Properties of Air Chart, the density of air at 60F and 30 psig is 0.232 lb/ft3 with a specific heat of 0.24 Btu/lb/F. The kW required can be calculated from the formula: ACFM x lbs/ft3 x 60 min x Cp x T kW = x SF 3412 Btu/kW Where: ACFM = Actual flow in ft3/min at inlet temperature and gauge pressure (psig) Lbs/ft3 = Actual density at inlet temperature and gauge pressure (psig) Cp = Specific heat of air or gas at inlet temperature and gauge pressure (psig) T = Temperature rise in F SF = Suggested Safety Factor kW = kW = 20 x 0.232 x 60 x 0.24 x (210 - 60F) x 1.2 3412 278.4 lbs/hr x 24 x 150 x 1.2 = 3.52 kW 3412 SCFM = 45 x (35 + 14.7) (70 + 460) x 14.7 psia (50 + 460)

Chart 236 Circulation Heaters Free Internal Cross Sectional Area

Pipe Body Nom. IPS (Std.) 2 3 5 8 10 12 14 16 18 Total Area (Ft2) 0.023 0.051 0.139 0.355 0.566 0.785 0.957 1.268 1.622 Free Area (Ft2) 0.018 0.044 0.124 0.303 0.481 0.696 0.847 1.091 1.357 No. 0.475" Elements 2 3 6 18 27 36 45 72 108

SFCM = 158.1 ft3/min Using the calculated SCFM in place of ACFM in equation A, the kW required is: kW = 158.1 x 0.073 x 60 x 0.2438 x (300 - 50) x 1.2 3412 kW = 14.8 kW

Determining Maximum Sheath & Chamber Temperatures

When heating air or gases in insulated pipe chambers or circulation heaters, the pipe wall temperature will normally exceed the outlet gas temperature. Excessively high wall and/or sheath temperatures can create an unsafe or dangerous condition. Maximum sheath and chamber temperatures can be estimated using the mass velocity of the gas and Graph G-237. In the above air heating example, assume a 4.5 kW Series 3 heater rated 23 W/in2 has been selected. From Chart 236, the free cross sectional area of a Series 3 (3 inch) heater is 0.044. Calculate mass velocity from the following equation: Mass Velocity (lbs/ft/sec) = Flow lbs/hr 3,600 Free area ft2

Mass Velocity = 1.75 lbs/ft/sec On Graph G-237, locate the mass velocity (1.75) on the horizontal axis. From that point, locate a 23 W/in2 curve. Read across to the vertical axis (sheath temperature rise above outlet temperature) to 880F. Adding 880F + 210F (outlet temp.) = 1090F sheath temperature. Averaging the sheath and outlet temperatures (1090F + 210F 2), yields a maximum chamber temperature of 650F. Since the maximum chamber wall temperature is less than 750F, a stock GCH heater with a carbon steel vessel and INCOLOY elements rated 23 W/in2 can be used.

Mass Velocity = 278 lbs/hr 3,600 0.044 ft2

When the density and specific heat of a gas at a specific temperature and pressure are unknown, the actual flow rate can be converted to a known pressure and temperature using the physical laws of gases. Example Heat 45 ACFM of Nitrogen (N2) at 35 psig from 50F to 300F. From the Physical and Thermodynamic Properties of Common Gases Chart, the density of Nitrogen at 70F is 0.073 lb/ft3 with a specific heat of 0.2438 Btu/lb/F. Convert 45 ACFM at 35 psig and 50F to SCFM of Nitrogen at 70F using the following formula: Actual psia Standard T SCFM = ACFM x x 14.7 psia Actual T SCFM = Std. ft3/min at 14.7 psia and 70F ACFM = Actual flow in ft3/min at inlet temperature and gauge pressure (psig) Actual psia = gauge pressure in lb/in2 + 14.7 psia 14.7 psia = absolute pressure in lb/in2 T = Rankine (F + 460)

Graph G-237 Sheath Temperature Vs. Mass Velocity

1400

1200
30

Maximum Sheath Temperature Rise Above Outlet Gas Temp. (F)

1000 Not Recommended

800

600

400

200

W 25 /In 2 W/ 2 3 In 2 W 2 0 / In 2 W/ 1 8 In 2 W/ I 15 n 2 W/ In 2 12 W /I n2 9W /In 2 6W /I n 2 3W /In 2

28

W / In 2

0 0 1.0 2.0 3.0 4.0 5.0 Mass Velocity (Lbs/Ft/Sec) 6.0 7.0

I-22